Carbonized component-based fuel pellet

ABSTRACT

With the rapid increase in the price of fossil fuels and growing concerns over climate change, the demand for renewable energy sources continues to increase. Densified biomass fuels are an alternative, renewable energy source that is becoming increasingly popular. A densified biomass with increased and controllable energy density is needed. Various embodiments of densified biomass and process to manufacture are taught herein.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/082,354 filed on Nov. 20, 2014 and incorporated herein, in its entirety, by reference.

BACKGROUND

With the rapid increase in the price of fossil fuels and growing concerns over climate change, the demand for renewable energy sources continues to increase. Densified biomass fuels are an alternative renewable energy source.

SUMMARY OF THE INVENTION

A carbonized component can be combined with at least one other component chosen from biomass, a lubricant, and a binder, and compressed into a densified biomass fuel. In one example, the carbonized component can be combined with a biomass and one or both of a lubricant and a binder. The carbonized component may be derived from the same or different type and/or species of biomass as the biomass component. The resulting densified biomass may have an energy density greater than 8000 BTU/lb. The addition of a carbonized component increases the energy density of densified biomass fuels; and the addition of selected amounts and/or types of carbonized components allows the energy density can be more accurately predicted and controlled in manufacture. Conversion of a wide variety of biomass to a carbonized component may allow a greater variety of feedstocks to be used as a densified biomass fuel.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages of the present invention will become apparent in the following detailed descriptions of the preferred embodiment with reference to the accompanying drawings, of which:

FIG. 1A shows an example process to make densified biomass;

FIG. 1B shows an example process to make a densified biomass;

FIG. 2A shows an example particle size distribution for the screened sawdust biomass;

FIG. 2B shows an example particle size distribution for the carbonized component; and

FIG. 3 shows an example biochar carbonized component content percentage against the energy density heat of combustion value;

FIG. 4 shows an example process to make densified biomass.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, the use of similar or the same symbols in different drawings typically indicate similar or identical items, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. One skilled in the art will recognize that the herein described components (e.g., operations), devices, objects, and the discussion accompanying them are used as examples for the sake of conceptual clarity and that various configuration modifications are contemplated. Consequently, as used herein, the specific exemplars set forth and the accompanying discussion are intended to be representative of their more general classes. In general, use of any specific exemplar is intended to be representative of its class, and the non-inclusion of specific components (e.g., operations), devices, and objects should not be taken as limiting.

The present application may use formal outline headings for clarity of presentation. However, it is to be understood that the outline headings are for presentation purposes, and that different types of subject matter may be discussed throughout the application (e.g., device(s)/structure(s) may be described under process(es)/operations heading(s) and/or process(es)/operations may be discussed under structure(s)/process(es) headings; and/or descriptions of single topics may span two or more topic headings). Hence, the use of the formal outline headings is not intended to be in any way limiting. By way of overview, embodiments provide improved densified biomass fuel and methods for manufacture.

Densified biomass fuels are typically made by the densification of woody or non-woody biomass. The densification process allows for non-uniform biomass material to be densified into a generally geometrically uniform product that can be handled, transported, and used in mostly standardized heating units, such as pellet stoves or industrial boilers. Densification may be accomplished by a cuber, briquetter, pellet mill, or extruder, for example. The requirements of a particular combustion system (pellet stove or industrial boilers), components of the combined carbonized mixture, manufacturing availability, costs, etc. may be factors in determining the appropriateness of determine the device used for densification.

The amount of energy a densified biomass releases, or its energy density, was previously dependent on the type of biomass material used. For example, woody biomass, such as Abies Grandis, commonly known as white fir, has a greater energy density than pellets produced from non-woody forms of biomass. Depending on the biomass, densification process, and various environmental factors, it has been difficult to predict and manufacture, with any kind of certainty, the energy density of a single piece of densified biomass or a package of densified biomass having a plurality of densified biomass pieces, for example, or at least specify a minim energy density of the single piece or package of densified biomass. Although densification processes are well known, most densified biomass fuels lack the energy density and/or predictability/uniformity that some combustion systems or user applications require. Additionally, currently manufactured densified biomass fuels are not resistant to moisture and lose their integrity when exposed to rain or dew. Consequently, densified biomass fuels need to be stored and transported in dry facilities thereby increasing the cost of manufacture and use. Also, for densified biomass fuels to be practical to use in residential or commercial combustion systems, a higher energy density, as compared to that of a standard pressed wood pellet, for example, is needed as well as predictable and/or minimum energy density.

Mixing a carbonized component to raw or dried biomass feedstock prior to densification will increase the energy density of densified biomass fuel as compared to standard pressed biomass, such as wood, pellets. The energy value can be determined and then controllably altered through the addition of a carbonized component which is of higher energy density per unit mass relative to typical raw biomass. Biomass feedstock may be wood, agricultural crops, organic waste (e.g. residential, commercial, and/or agricultural waste such as straw, corn cobs, fruit pomace, yard waste, etc.), or other lingo-cellulosic materials, individually or in combination. The biomass feedstock may be in particle form and/or shredded form or combination thereof or in any other appropriate form. The biomass may be of a single type (e.g., agricultural waste, etc.) or of a single species (e.g. straw) for simplicity in sourcing but may also be provided as combination two or more multiple types or species of biomass (e.g., wood and non-wood, or straw and grass). A carbonized component may be an organic substance that has been converted into carbon or a carbon-containing residue through any appropriate process such as pyrolysis, destructive distillation, or other means obtaining the same or similar results. For example, biochar is a solid material obtained from the carbonization, through pyrolysis or heating in a low/no oxygen environment, of biomass. Coal is another example of a carbonized component. Coke, coal gas, gas carbon, coal tar, Buckministerfullerene, ammonia liquor, and “coal oil” are examples of commercially available carbonized components that are obtained from the destructive distillation of coal. It will be appreciated that other forms of carbon may also be used as a carbonized component as desired for a particular application. The carbonized component may be of a single type (e.g., biomass derivative or non-biomass, wood or non-wood) or may be a combination. The carbonized component may include a single or multiple types of carbonized components where the species may include the type of biomass derivative (e.g., white fir wood). The carbonized component may be derived from the same or different type or even species of biomass as the biomass components (e.g., the carbonized component may be derived from wood products and the biomass be of the wood type, the carbonized component may be derived from white fir and the biomass may include white fir, etc.). The combination of a biomass feedstock and carbonized component with an optional binder and/or lubricant can result in a densified biomass which is structurally stable with heating values (energy density) (HHV) in the range of 7,500-11,000 BTU/lb.

Referring generally to the FIGS. 1A and 1B, in various embodiments, a carbonized component 10 can be combined in a mixer 20 or densifier 22 with at least one other component chosen from biomass 12, a lubricant 14, and a binder 16 to form a combined carbonized mixture 24. The biomass 12 can be a single type of biomass, e.g., a particular type of wood such as white fir, or a combination of various types of biomass, woody or non-wood. Similarly, the lubricant 14 can be any suitable lubricant or combination of lubricants; and the binder 16 can be any suitable single type of binder or combination of binders. The combined carbonized mixture 24 can be compressed in a densifier 22 into a densified biomass fuel 18. Densification of the combined carbonized mixture 24 in the densifier 22 may be accomplished by any appropriate equipment and/or process such as a cuber, pellet mill, or extruder, for example. In some examples, the biomass and/or combined carbonized component, biomass, lubricant, and/or binder can be dried prior to densification. The drying process can be accomplished in a dryer, oven, natural ambient conditions, etc. In various embodiments, moisture in the form of liquid water or steam, for example, may be added to the carbonized component 10 and at least one other component chosen from biomass 12, lubricant 14, and binder 16. The moisture can be added to any one or more components (e.g., the carbonized component, the biomass, the binder, and/or the lubricant) before mixing into the combined carbonized mixture, or may be added to the combined carbonized mixture, or may additionally or alternatively added to the combined carbonized mixture but before densification. The additional moisture may promote even heating of the combined carbonized mixture 24 during the densification process.

During densification, heating of the combined carbonized mixture 24 may cause softening of lignin and hemicellulose. Upon cooling, the lignin hardens and structurally stabilizes the densified biomass 18. Depending upon the biomass 12 used in the combination carbonized mixture 24, densified biomass 18 may have higher energy densities that those created using existing biomass alone without a carbonized component.

In various embodiments, the binder 16 may be included in the combined carbonized mixture 24 to enhance a biomass 12 which contains small amounts of lignin. For example, some biomass feedstock component 12 may include a lignin content of only 10-20% wt lignin (e.g., grasses) which may lead to structural instability of the densified biomass or require specialized processing or handling. The binder 16 may be any suitable binder, including without limitation, biopolymers or manmade polymers. Biopolymers may include, for example, corn starch, cotton, etc. Binders may also be derived from non-bio sources (e.g., man-made); for example, a plastic such as high density polyethylene (HDPE). The HDPE may be obtained from refuse such as material destined for a landfills (e.g., recycled or re-used) or may be manufactured. The binder 16 may partially break down during heating in the densifier 22, and may harden and structurally stabilize densified biomass 18. In various embodiments, the binder 16 used may be hydrophobic which in one example includes a polymer.

In various embodiments, a carbonized component 10 may be mixed with only a binder 16 before densification 22. In such embodiments, the ratio of carbonized component 10 to binder 16 may be low in order to form a more structurally densified biomass 18. In some embodiments of densified biomass 18, based on dry weight mass, the combined carbonized mixture 24 may include 80-90% carbonized component and 0-20% binder 16 and in some cases may be 5% binder 16. A binder may be advantageous for mixing in a combined carbonized mixture 24 with higher ratios of carbonized component 10 compared to biomass 12 to form a densified biomass 18 that is structurally stable (e.g., a durability index of a selected value). The binder 16 may be added in a similar fashion as the carbonized component to adjust and/or increase the energy density of the densified biomass 18. Binders 16 may be used within the mixer 20 and/or applied after the densifier 22 to fill pores that may occur in the final densified biomass (e.g. pellet).

Lubricant 14 may be any appropriate lubricant including any one or more of water or oil based which may include, vegetable oil, or other bio-oils (including bio-oils from pyrolysis of bio-based materials, naturally derived oils, etc.), petro-chemical based oils, synthetic lubricants derived from petroleum or natural gas origins (such as olefins, esters, glycols, paraffins, etc.), etc. Lubricants 14 derived from bio-oils may also serve as a binder 16 due to the presence of reducible hydrocarbons and oxygenates. The lubricant 14 may improve flow of the combined carbonized mixture 24 through the densification process, such as improving flow of the mixture into die for formation of the densified biomass 18 (e.g., pucks, briquettes, logs and/or pellets) in the densifier 22. The lubricant may also act to conduct heat evenly throughout the mixture during the densification process.

Some lubricants 14, such as oils, may have hydrophobic properties. In various embodiments, the addition of oil as a lubricant 14 additionally decreases the roughness of densified biomass creating an enhanced barrier to moisture. Oils may be added to the carbonized component 10 in the mixer 20, as discussed above, or applied (e.g., misted, sprayed, coated, etc.) onto the surface of densified biomass 18 after leaving the densifier 22 or any other suitable time afterward. In various embodiments, polymers which dry may also be applied as appropriate onto densified biomass 18 after the densifier 22. Exemplary drying polymers include alcohol soluble polymers like ethylene glycol or poly vinyl alcohol.

Mixing biomass 12 with a carbonized component 10 has several advantages including a higher energy density. Carbon has an energy density of ˜14,500 BTU/lb. Biochar or other carbonized components 10 can be formed with energy densities ranging from 5,100 to 19,000 BTU/lb. Dried wood (an example of a biomass 12) has an energy density of ˜8,000 BTU/lb. Mixing a carbonized component 10 that has an energy density greater than 8,000 BTU/lb with the biomass 12 containing wood during or prior to densification may lead to a densified biomass 18 with a higher overall energy density than if made from wood (or other biomass) alone. Mixing biomass 12 with a carbonized component 10 produced from the same biomass 12 may produce a densified fuel pellet with an energy density (by mass and volume) higher than that of a pellet produced only from the biomass alone. For example, the carbonized component 10 can be produced from a selected biomass 12 through an appropriate carbonization process (converted into carbon or a carbon-containing residue through any appropriate process such as pyrolysis, destructive distillation, or other means obtaining the same or similar result) and the carbonized component 10 can then be combined in the mixer 20 with a biomass 12 of the same type and may include one or more of a lubricant 14 and/or binder 16.

In various embodiments, a first biomass 12 a with low lignin content may be carbonized into a carbonized component 10 and mixed with a second type of biomass 12 b with a higher lignin content than the first biomass 12 a, yielding a densified biomass 18 that has an energy density which is larger than the energy density of the first biomass 12 a and second biomass 12 b together. Biomass feedstock with low lignin content includes grasses, agricultural crops and agricultural residues, food wastes, amongst others.

In various embodiments, the ratio of the carbonized components to at least one component chosen from biomass, lubricant, and binder may be adjusted to provide densified biomass with an energy content or energy density at or above a preselected value. In various embodiments, the mass density of the densified form may be greater than 0.8 g/cc., the mass density may be greater than 1 g/cc., the mass density may be greater than 1.2 g/cc. In various embodiments the energy density may be greater than 8000 BTU/lb., the mass energy density may be greater than 9000 BTU/lb., and/or the mass energy density may be greater than 10,000 BTU/lb.

In one embodiment, a carbonized component 10 having an energy density of 14,500 BTU/lb maybe mixed with biomass of 8,000 BTU/lb (such as some woody biomass) at a ratio of 25% biochar to 75% woody biomass to produce a densified biomass having 9,625 BTU/lb. The ratio of carbonized component 10 to biomass 12 may be adjusted to account for the type of biomass being used (e.g., average energy density of the biomass, average desired energy density of the densified biomass, biomass lignin content, etc.), the desired durability of the densified biomass, the final combustion system requirements, etc.

In various embodiments, the ratio of carbonized component 10 to at least one component chosen from biomass 12, a lubricant 14, and a binder 16 may be adjusted to provide densified biomass 18 having a predetermined or exceeding a predetermined threshold grindability rating (such as the Hargrove Grindability Index or other appropriate grindability rating). In one exemplary embodiment, the densified biomass 18 exhibits a grindability rating resulting in less than a 100-micron average particle size. In another exemplary embodiment, the densified biomass 18 exhibits a grindability rating resulting in less than a 75-micron average particle size. In another exemplary embodiment, the densified biomass 18 exhibits a grindability rating resulting in less than a 50-micron average particle size. Generally increasing the ratio of carbonized component to biomass and/or lubricant and binder can increase the grindability as char can typically be brittle. The densified biomass may be formed using a combination of carbonized component and at least one of a biomass, lubricant and binder to have a similar grindability index as coal under the Hardgroves Grindability index (e.g. ball milling a source material until a percentage of the source material can be filtered through a specified mesh size) or any other grindability rating or standard, and/or a similar particle size distribution as coal or any other selected product or Hardgroves index which may be selected to match expectations and/or requirements of existing or anticipated combustion or processing equipment. Some existing coal plants have a typical coal particle size distribution of approximately 75 micrometers with a range of 40-250 micrometers.

The ratio of the carbonized component 10 to at least one component chosen from biomass 12, lubricant 14, and binder 16 may be adjusted to provide densified biomass 18 that is resistant to moisture. Some carbonized components such as biochar is less susceptible to absorbing moisture than some forms of biomass feedstock. In various embodiments, a larger concentration of a carbonized component 10 as compared to biomass 12 may make densified biomass less susceptible to the effects of moisture. As noted above, addition of some types of lubricants and/or binders may also increase the moisture resistance of the densified biomass 18.

In some embodiments of densified biomass, based on dry weight mass, the combined carbonized mixture 24 may include 10-80% carbonized component, 10-80% biomass, 0-30% binder, 0-20% lubricant. In one embodiment, 10-40% carbonized component, 50-80% biomass, 5% binder, and 5% lubricant may be used. The densified biomass 18 may be densified using a densifier 22 which may include conventional pelleting processes via ring or flat die configuration, briquetting, and/or extrusion (screw- or ram-based systems) or any other appropriate method and/or equipment.

FIG. 4 illustrates an example method 400 of manufacturing a densified biomass of which not all steps or acts will be required and may be optionally included as appropriate. The biomass component (if included in the combined carbonized mixture may be appropriately sized 410 using any suitable technique, such as screening, filtering, agitating, etc. The biomass may be dried 412 to a selected range or approximate water content using any appropriate technique such as drying in ambient conditions, furnace, heater, air flow, etc. The binder may be selected 414 to augment the lignin content (or lack thereof) in the carbonized component and/or the biomass. The lubricant may be selected 416 to augment the manufacturing consistency of the combined carbonized component for densification and/or potential benefits of moisture control (hydrophobic qualities), etc. The carbonized component may be selected and sized 418 using any appropriate technique such as screening, filtering, agitating, etc. The carbonized component may be optionally dried 420 using any appropriate technique such as ambient or controlled conditions, air flow, heating, etc. The carbonized component may be combined or mixed 422 with the biomass, lubricant, and/or binder in selected quantities into a combined carbonized mixture to achieve the desired densified biomass stability, heat combustion qualities, and/or any other quality of the densified biomass or resulting combustion system. The combined carbonized mixture may be dried 424 using any suitable technique including drying in ambient or controlled conditions, heater, air flow, etc. The combined carbonized mixture may be densified 426 into a densified biomass using any suitable technique and equipment such as pressing, extrusion, etc. and formed into any suitable form such as pellets, pucks, etc.

Prior to densification 426, moisture in the form of liquid water or steam, for example, may be added 435 to the combined carbonized mixture. The moisture may be added in any suitable technique such as spraying, flow, etc. The moisture may be added and/or removed to achieve a combined carbonized mixture having the desired and preselected water content. The preselected water content may be approximately 10% by mass weight but may be less than 31%. An optional binder (which may have hydrophobic qualities and which may be different or the same as the binder if used in the combined carbonized component) may be applied 430 to the densified biomass and/or an optional lubricant (which may have hydrophobic qualities and which may be the same as or different from the lubricant if used in the combined carbonized mixture) may be applied 432 to the densified biomass. If an optional binder and/or lubricant is applied to 432 to the densified biomass, then the densified biomass may be dried 428 using any suitable technique such as drying in ambient or controlled conditions, heater, air flow, etc. The densified biomass may then be combusted 434 in a combustion system to generate heat and/or energy.

Potential forms of densified biomass 18 include pellets made by mixing a carbon component 24, biomass feedstock 12, binder 16, and lubricant 14; where the carbon component 24 is biochar (derived from a woody biomass), the biomass feedstock 12 is sawdust obtained from band mill sawdust residuals of Grand Fir, the binder 16 is a powdered high density polyethylene (“HDPE”) (MFI—0.3-0.5), and the lubricant is canola oil. The weight percentages for some embodiments are shown in Table 1 although it is to be appreciated that other ratios and/or types of carbonized component, biomass feedstock, lubricant, and/or binder may be used as appropriate.

TABLE 1 Example Formulations for the biochar energy pellets Component Level (%) Component Run #1 Run #2 Run #3 Run #4 Run #5 Grand fir sawdust 90 80 70 60 50 Biochar 0 10 20 30 40 Canola oil 5 5 5 5 5 HDPE 5 5 5 5 5

The heat of combustion for each component in Table 1 and the pellets manufactured at each “run” was determined utilizing a bomb calorimeter. Testing guidelines prescribed by ASTM D5865-07, 2007, Standard Test Method for Gross Calorific Value of Coal and Coke, West Conshocken, Pa., ASTM Int'l, were followed with a sample size of n=5.

Based upon sawdust residuals size and shape, sawdust residuals may be appropriate biomass feedstocks 12 for making most densified biomass 18 fuel pellets. However, to make a consistent product, screening and drying the sawdust residuals (biomass 12) may be desired. A mechanical classifier with a 0.375″ screen may be used to separate out “overs” or larger particles, although it is to be appreciated that other sizes any or screening methods may be used as appropriate. The screened biomass 12 material may be allowed to air dry in ambient conditions for 2 days (although it is to be appreciated that other drying and/or times may be appropriate) to a moisture content below 31% (between 23-31%) before combination in the mixer with the carbonized component.

The particle size distribution for the screened sawdust (biomass 12) and the carbonized component 10 are shown in FIGS. 2A and 2B respectively. As shown in the example distribution of FIG. 2B, the carbonized component 10 may have a bimodal population of particles, where there are significant amounts of large (+0.425 mm) and fine (<0.106 mm) particles. As shown in the example distribution of FIG. 2A, the biomass feedstock 12 (which in some cases like here may be Grand Fir sawdust) particle size distribution has a common bell-shaped curve of a normal distribution. The screen sizes used to characterize the carbonized component 10 may be much smaller than the screens used for the biomass feedstock 12 to characterize the possibility or existence of finer particles within the carbonized component. The biomass feedstock Grand Fir sawdust may be allowed to dry using any appropriate technique including furnace/oven, ambient conditions, etc. The Grand Fir sawdust utilized in the combined carbonized mixture 24 may have a moisture content range between 23-31%. The carbonized component 10 moisture content is approximately 5.3%.

The heat of combustion (energy density in BTU/lb) for the individual components and the final densified biomass 18 pellets of Table 1 are shown in Tables 2A, 2B, and 3 respectively. The data in Table 2A shows actual heat of combustion values of the components prior to mixing or densifying and Table 2B shows the reference values of heat combustion values of the components prior to mixing or densifying. The Grand Fir wood biomass feedstock 12 has the lowest heat of combustion while HDPE (binder 16) has the highest heat of combustion.

TABLE 2A Actual Bomb calorimetric values for the individual component prior to pelletization. Heat of Heat of Drying combustion combustion Component Method (Btu/lb) (KJ/kg) Grand fir sawdust (biomass) Oven dry  8,705 ± 40 20,246 ± 90  Biochar (carbonized Over dry 12,738 ± 96 29,628 ± 223 component) Canola oil (lubricant) N/A 17,236 ± 24 40,090 ± 57  HDPE (binder) N/A 20,212 ± 82 47,014 ± 191

TABLE 3 Physical and calorimetric values for the pelletized material. Formulation Moisture Content Pellet wt % (wt %) Density Heat of combustion Run # Biochar Feedstock Pellets (g/cm³) (Btu/lb) (KJ/kg) 1 0 14.2 ± 0.7 7.5 ± 0.06 1.25 ± 0.01  9,289 ± 57 21,605 ± 134 2 10 23.7 ± 0.1 5.8 ± 0.07 1.29 ± 0.02  9,782 ± 58 22,753 ± 135 3 20 18.3 ± 0.6 3.2 ± 0.09 1.29 ± 0.03 10,069 ± 43 23,419 ± 101 4 30 22.4 ± 0.1 3.1 ± 0.09 1.26 ± 0.02 10,460 ± 12 24,331 ± 27  5 40 13.9 ± 0.2 2.9 ± 0.10 1.32 ± 0.04 10,977 ± 61 25,532 ± 142

By using the Rule of Mixtures (ROM) in the following equation, a summation of the weight fraction (WF) of each component (i) and their component heat of combustion (HC) was used to predict the composite pellet HC.

${{Predicted}\mspace{14mu} {HC}} = {\sum\limits_{i = 0}^{n}\; {{WF}_{i}*{HC}_{i}}}$

The plot in FIG. 3 shows the increasing trend with the addition of biochar (carbonized component 10) in the formulation. The ROM shows a similar increasing trend. However, the overall results show a higher predicted HC than the experimental results. The likely explanation for this discrepancy is that the moisture was removed during the test of the individual components (the wood biomass and biochar carbonized component), whereas the densified biomass pellet HC values were based upon as-is MCs in the range of 2.9-7.5% (Table 3). To validate the influence of moisture, the pellets were oven-dried at 103° C. for 24 hours and tested. The experimental results of the dried pellets showed a higher calorific value than the ROM at the lower char levels, followed by a shift at the 20% char level. A similar shift was seen with the undried pellets. Since this trend has been observed in both data sets, the shift might be indicative of potential interactions or slight chemical alterations of the pellet composite. The data provides an assessment of the influence biochar carbonized component may have on the combustion characteristics of wood-based energy pellets.

The bomb calorimetry tests performed followed closely with literature values and showed an increasing HC trend that one would expect to observe with the addition of biochar. The ROM provided a simply model to predict the combustion values with reasonable accuracy, which will be a valuable asset for any future work and valuable for creating a mixed biomass product with a minimum energy value at or below a selected value.

TABLE 2B Reference values for the HC of the individual components in the pellet formulation. Component HHV (Btu/lb) HHV (kJ/kg) Grand fir  8,738 20,235 Biochar 5,086~19,003 11,830~44,200 Canola oil 17,102 39,780 HDPE 19,905 46,300

Although the present invention has been described in connection with embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departure from the spirit and scope of the invention as defined in the appended claims.

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations are not expressly set forth herein for sake of clarity.

The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures may be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “operably connected”, or “operably coupled,” to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable,” to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically mateable and/or physically interacting components, and/or wirelessly interactable, and/or wirelessly interacting components, and/or logically interacting, and/or logically interactable components.

In some instances, one or more components may be referred to herein as “configured to,” “configured by,” “configurable to,” “operable/operative to,” “adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Those skilled in the art will recognize that such terms (e.g., “configured to”) can generally encompass active-state components and/or inactive-state components and/or standby-state components, unless context requires otherwise.

While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from the subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the subject matter described herein. It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B.”

With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although various operational flows are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated, or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.

Those skilled in the art will appreciate that the foregoing specific exemplary processes and/or devices and/or technologies are representative of more general processes and/or devices and/or technologies taught elsewhere herein, such as in the claims filed herewith and/or elsewhere in the present application.

While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims. 

What is claimed is:
 1. A process for manufacturing a densified biomass having an energy density of greater than 8000 BTU/lb. comprising the steps of: a) combining a carbonized component and at least one other component chosen from the group consisting of biomass, lubricant, and binder to form a combined carbonized component; and b) densifying the combined carbonized mixture to form the densified biomass.
 2. The process according to claim 1 where the combined carbonized mixture, based on dry weight, is 10-80% carbonized component, 0-80% biomass, 0-30% binder, 0-20% lubricant.
 3. The process according to claim 1 where the combined carbonized mixture, based on dry weight, is 10-40% carbonized component, 50-80% biomass, and 0-5% binder, and 0-5% lubricant.
 4. The process according to claim 1 where the carbonized mixture, based on dry weight, is 10-40% carbonized component, 50-80% biomass, and 5% binder, and 5% lubricant.
 5. The process according to claim 1 where the combined carbonized mixture includes the carbonized component and the biomass.
 6. The process according to claim 5 where the biomass is comprised of both woody type and non-woody type biomasses.
 7. The process according to claim 1 where the combined carbonized mixture includes the carbonized component and the binder.
 8. The process according to claim 7 where the combined carbonized mixture, based on dry weight, is 80-90% carbonized component and 0-20% binder.
 9. The process according to claim 7 where the binder includes at least one chosen from a bio-polymer or non-bio polymer.
 10. The process according to claim 9 where the binder includes high density polyethylene.
 11. The process according to claim 7 where the binder includes a hydrophobic polymer.
 12. The process according to claim 1 where the combined carbonized component includes the carbonized component and the lubricant, the lubricant is at least one chosen from the group consisting of bio-oils, petro-based oils, and synthetic lubricant.
 13. The process according to claim 12 where the lubricant includes at least one bio-oil.
 14. The process according to claim 1 where the lubricant includes a hydrophobic lubricant.
 15. The process according to claim 1 where the carbonized component includes a carbonized component derived from a second biomass that has a low lignin content.
 16. The process according to claim 1, where the combined carbonized component includes the carbonized component and a biomass.
 17. The process according to claim 16, where the second biomass is the same type as the biomass.
 18. The process according to claim 17, where the second biomass is the same species as the biomass.
 19. The process according to claim 16 where the biomass is woody type, non-woody type, or a combination thereof.
 20. The process according to claim 1 where the carbonized component is an organic substance converted into carbon or carbon-containing residue.
 21. The process according to claim 1 where densifying includes pelletization.
 22. The process according to claim 1 further comprising drying the combined carbonized mixture prior to densifying.
 23. The process according to claim 1 further comprising applying a second lubricant to the densified biomass after densification.
 24. The process according to claim 1 further comprising applying a second binder to the densified biomass after densification.
 25. A densified biomass having an energy density of greater than 8000 BTU/lb. comprising the steps of: a) mixing a carbonized component and at least one other component chosen from the group consisting of biomass, lubricant, and binder to form a combined carbonized mixture; i) where the carbonized component includes biochar derived from a second biomass of a woody type; ii) where the biomass includes woody biomass; iii) where the lubricant includes bio-oil; iv) where the binder includes high density polyethylene. b) densifying the combined carbonized mixture into the densified biomass; c) applying a hydrophobic component to the densified biomass.
 26. The densified biomass according to claim 25 where the combined carbonized mixture, based on dry weight, is 10-80% carbonized component, 0-80% biomass, 0-30% binder, 0-20% lubricant.
 27. The densified biomass according to claim 25 where the combined carbonized mixture, based on dry weight, is 10-40% carbonized component, 50-80% biomass, and 0-5% binder, and 0-5% lubricant.
 28. The densified biomass according to claim 25 where the carbonized mixture, based on dry weight, is 10-40% carbonized component, 50-80% biomass, and 5% binder, and 5% lubricant.
 29. The densified biomass according to claim 25 where the combined carbonized mixture includes the carbonized component and the biomass.
 30. The densified biomass according to claim 29 where the combined carbonized mixture includes the carbonized component and the binder.
 31. The densified biomass according to claim 31 where the combined carbonized mixture, based on dry weight, is 80-90% carbonized component and 0-20% binder.
 32. The densified biomass according to claim 25 where combined carbonized mixture includes the carbonized component, the biomass and the lubricant, the lubricant.
 33. The densified biomass according to claim 39, where the second biomass is of the same species as the biomass.
 34. The densified biomass according to claim 26 where the densifying includes pellitization.
 35. The densified biomass according to claim 26 further comprising creating a selected moisture content in the combined carbonized mixture prior to densification.
 36. The densified biomass according to claim 35, where creating a selected moisture content includes adding moisture to the combined carbonized mixture.
 37. The densified biomass according to claim 35, where creating the selected moisture content includes drying the combined carbonized component.
 38. The densified biomass according to claim 26 where a second lubricant is applied to the densified biomass after densification and includes a polymer.
 39. The densified biomass according to claim 26 where a second binder is applied to the densified biomass after densification. 